Wood Magazine July 2017f

SINGLE-STAGE DUST COLLECTORS TESTEDp.36 ISSUE 247 JULY 2017

®

The World’s Leading Woodworking Resource

Multi-purpose

p.24

Plus Great Plans Icebox Chest Jigsaw Circle Jig Toy WWII Jeep

p.42

p.14

p.48

Plumb Your Shop for Air p.54

Phone/Tablet Charging Station p.30

SUMMER SALE April 10 − July 10

2017

PURVEYORS OF FINE MACHINERY®, SINCE 1983! 14" DELUXE BANDSAW

17" HEAVY-DUTY BANDSAW

• Motor: 1 HP, 110V/220V, prewired 110V, single-phase, TEFC, 1725 RPM • Amps: 11A at 110V, 5.5A at 220V • Table size: 14" x 14" x 11⁄2" • Table tilt: 10° L, 45° R • Floor-to-table height: 43" • Cutting capacity/throat: 131⁄2" • Max. cutting height: 6" • Blade size: 931⁄2" (1⁄8" to 3⁄4" wide) • Blade speed: 1800 and 3100 FPM • Overall size: 27" W x 671⁄2" H x 30" D • Footprint: 231⁄2" L x 161⁄2" W • Approx. shipping weight: 246 lbs.

• Motor: 2 HP, 110V/220V, single-phase, TEFC, prewired 220V • RPM: 1725 • Amps: 20A at 110V, 10A at 220V • Precision-ground cast iron table size: 17" x 17" x 11⁄2" • Table tilt: 45° R, 10° L • Floor-to-table height: 371⁄2" • Cutting capacity/throat: 161⁄4" • Blade length: 1311⁄2" (1⁄8" to 1" wide) • Approx. shipping weight: 342 lbs.

G0555LX $57500

30TH ANNIVERSARY EDITION

177335

$

89

SALE $52500

shipping

lower 48 states

10" HYBRID TABLE SAW

WITH RIVING KNIFE

$

89500 SALE $75000

109

shipping

lower 48 states

G0690

$

157500 SALE

WITH RIVING KNIFE & EXTENSION RAILS

G0691

172500 SALE $159500

$

8" JOINTERS • Motor: 3 HP, 240V, single-phase, TEFC, 3450 RPM, 15A • Max. depth of cut: 1⁄8" • Max. rabbeting capacity: 1⁄2" • • Cutterhead diameter: 3", Speed: 4800 • Cutterhead knives: 4 HSS; 8" x 3⁄4" x 1 • • Deluxe cast iron fence size: 35" L x 5" H • Approx. shipping weight: 522 lbs.

86500 SALE $79500

4 KNIFE CUTTERHEAD

89500 G0656X ONLY $1295 G0656 ONLY

shipping lower 48 states

15" PLANERS

• • • • • • • • • • • •

• • • • • • • • • •

Motor: 3 HP, 240V, single-phase, 14A Max. cutting width: 15", depth: 1⁄8" Max. stock thickness: 63⁄8", Min: 1⁄4" Min. stock length: 63⁄8" Feed rate: 16 and 30 FPM Cutterhead diameter: 3" PLEASE SEE T27650 FOR Number of knives: 3 HSS 1 THE OPTIONAL Knife size: 15" x 1" x ⁄8" STAND Cutterhead speed: 5000 RPM Table size: 201⁄8" x 15" x 31⁄2" Overall size: 32" W x 28" D x 231⁄2" H Approx. shipping weight: 382 lbs.

G0815

17WOODM 18797

1150

00

$

00

SALE 925

Motor: 3 HP, 240V, single-phase, 15A Max. cutting width: 15", Depth: 1⁄8" Max. stock thickness: 8", Min: 3⁄16" Min. stock length: 8" Feed rate: 16 & 30 FPM Cutterhead diameter: 3", Speed: 4800 RPM Power feed rollers: solid serrated steel Precision-ground table size: 15" x 20" Overall size: 321⁄2" W x 42" D x 457⁄8" H Approx. shipping weight: 675 lbs. (G0453), 672lbs. (G0453Z)

3 KNIFE CUTTERHEAD

$

159

shipping

lower 48 states

$

1250 G0453Z ONLY 1795 G0453 ONLY SPIRAL CUTTERHEAD

$

159

INCLUDES A 3 HP SHOWN LEESON® MOTOR

shipping

lower 48 states

$

G0656 SHOWN

SPIRAL CUTTERHEAD

15" HEAVY-DUTY PLANER

$

shipping

lower 48 states

$

• Motor: 1.5 HP, 120V/240V, single-phase, 15A/7.5A, prewired 120V • Max. width of cut: 6" • Max. depth of cut: 1⁄8" • Max. rabbeting capacity: 1⁄2" • Cutterhead diameter: 21⁄2" • Cutterhead speed: 4800 RPM 208624 • Table size: 71⁄2" x 46" • Floor-to-table height: 321⁄2" FREE PAIR OF SAFETY • Cuts per minute: 19,200 PUSH • Fence size: 5" H x 35" L BLOCKS • Fence adjustment stops at 45°, 90°, 135° • Overall size: 46" L x 271⁄2" W x 49" H • Approx. shipping weight: 268 lbs. $

109

232857

6" JOINTER WITH SPIRAL CUTTERHEAD

G0452Z

$

• Motor: 3 HP, 220V, single-phase, 12.8A • Precision-ground cast iron table with extension measures: 27" x 40" (G0690), 27" x 743⁄4" (G0691) • Floor-to-table height: 34" • Arbor: 5⁄8" • Arbor speed: 4300 RPM • Max. dado width: 13⁄16" • Capacity @ 90º: 31⁄8", @ 45º: 23⁄16" • Max. rip capacity: 291 • 557 lbs. (G0691)

• • Amps: 15A at 120V, 7.5A at 240V • Precision-ground cast iron table with wings measures: 401⁄2" W x 27" D • Floor-to-table height: 353⁄8" • Arbor: 5⁄8" • Arbor speed: 3450 RPM • Max. depth of cut: @ 90° 31⁄4", 45° 21⁄4" • Rip capacity: 31" R, 16 3/4" L • Overall size: 64" W x 401⁄4" D x 351⁄2" H • Footprint: 21" L x 191⁄2" W • Approx. shipping weight: 371 lbs. $

G0513ANV $92500 SALE $87500 10" CABINET TABLE SAWS

WITH RIVING KNIFE & IMPROVED FENCE

G0771Z

MADE IN AN ISO 9001 FACTORY

$

TECHNICAL SERVICE: 570-546-9663 • FAX: 800-438-5901 2 GREAT SHOWROOMS! BELLINGHAM, WA • SPRINGFIELD, MO

208624

BUILT-IN MOBILE BASE!

TAKING MEASURE

Better Homes and Gardens®

WOOD

®

July 2017

Vol. 34, No. 3

Issue No. 247

EDITORIAL CONTENT CHIEF DAVE CAMPBELL DEPUTY EDITOR CRAIG RUEGSEGGER ART DIRECTOR KARL EHLERS DIGITAL CONTENT MANAGER LUCAS PETERS SENIOR DESIGN EDITOR KEVIN BOYLE DESIGN EDITOR JOHN OLSON TOOLS EDITOR BOB HUNTER ADMINISTRATIVE ASSISTANT SHERYL MUNYON CONTRIBUTING CRAFTSMEN JIM HEAVEY, MATT SEILER, BRIAN SIMMONS, BOB BAKER, BRIAN BERGSTROM, KENT WELSH PHOTOGRAPHERS CARSON DOWNING, JASON DONNELLY CONTRIBUTING EDITORS LARRY JOHNSTON, BILL KRIER, RANDY MAXEY CONTRIBUTING ILLUSTRATORS LORNA JOHNSON, ROXANNE LEMOINE, KURT SCHULTZ PROOFREADERS SAM CADY, BABS KLEIN, IRA LACHER ADVERTISING AND MARKETING VICE PRESIDENT & GROUP PUBLISHER SCOTT MORTIMER GROUP BUSINESS DEVELOPMENT DIRECTOR CURT BLADES ADVERTISING ACCOUNT EXECUTIVE DANIEL WELLS ONLINE MEDIA KIT WOODMAGAZINE.COM/MEDIAKIT BUSINESS MANAGER DARREN TOLLEFSON CONSUMER MARKETING MANAGER BLAINE ROURICK

Get plans for this intarsia American flag at woodmagazine.com/intarsiaflags. The plans also include the Canadian flag.

PRODUCTION MANAGER SANDY WILLIAMS PREPRESS DESKTOP SPECIALIST RANDY J. MANNING COLOR QUALITY ANALYST PAMELA POWERS MEREDITH NATIONAL MEDIA GROUP PRESIDENT JON WERTHER PRESIDENT AND GENERAL MANAGER OF MEREDITH MAGAZINES DOUG OLSON PRESIDENT OF MEREDITH DIGITAL STAN PAVLOVSKY

A time (and place) to chill M

y kids got me addicted to the hiphop musical Hamilton, a biography of U.S. founding father Alexander Hamilton. His often-contentious personal and political life ended prematurely— spoiler alert—in a predawn duel with rival Aaron Burr (sir). When I first listened to the cast recording, I found myself surprised, and oddly comforted, that the political climate then wasn’t that different from today, 213 years after Hamilton’s death. Again, nerves seem to be close to the surface, and the tension spills over into everyday life. An advertiser runs the same “buy American-made” message they’ve run without complaint for years, and I get emails from offended Canadians. Even the apolitical posts on our woodworking-exclusive Facebook page sometimes draw disproportionate ire. We’re so blessed as woodworkers to have a hobby into which we can escape from the

news (fake or otherwise). I suggest just retreating into the room where it happens. Turn off the TV and turn on your tablesaw. Log out of the computer and make something beautiful out of a log. Enjoy the peaceful process of sharpening your chisels instead of dulling your mind on social media. Rather than building animosity, build the latest homage to our brave servicemen and women on page 48. Be a little subversive and take a shot at the icebox-with-a-secret project on page 42 (which, ironically, doesn’t chill). I promise, as long as you’re enjoying time in the shop, you’re not throwing away your shot. See you in the shop!

[email protected] Facebook and Twitter: @WOODeditor

PRESIDENT OF CONSUMER PRODUCTS TOM WITSCHI CHIEF REVENUE OFFICER MICHAEL BROWNSTEIN CHIEF MARKETING OFFICER NANCY WEBER CHIEF DATA AND INSIGHTS OFFICER ALYSIA BORSA SENIOR VICE PRESIDENTS CONSUMER REVENUE ANDY WILSON DIGITAL SALES MARC ROTHSCHILD RESEARCH SOLUTIONS BRITTA CLEVELAND DIGITAL VIDEO MELINDA LEE CHIEF DIGITAL OFFICER MATT MINOFF VICE PRESIDENTS FINANCIAL CHRIS SUSIL BUSINESS PLANNING AND ANALYSIS RON SILVERSTONE CONTENT LICENSING LARRY SOMMERS CORPORATE SALES BRIAN KIGHTLINGER DIGITAL SALES MARLA NEWMAN DIRECT MEDIA PATTI FOLLO BRAND LICENSING ELISE CONTARSY HUMAN RESOURCES DINA NATHANSON STRATEGIC SOURCING, NEWSSTAND, PRODUCTION CHUCK HOWELL CONSUMER MARKETING STEVE CROWE

CHAIRMAN AND CHIEF EXECUTIVE OFFICER STEPHEN M. LACY PRESIDENT AND CHIEF OPERATING OFFICER TOM HARTY PRESIDENT, MEREDITH LOCAL MEDIA GROUP PAUL KARPOWICZ CHIEF FINANCIAL OFFICER JOSEPH CERYANEC CHIEF DEVELOPMENT OFFICER JOHN ZIESER VICE CHAIRMAN MELL MEREDITH FRAZIER IN MEMORIAM E.T. MEREDITH III (1933–2003) X For subscription help: Online: woodmagazine.com/myaccount E-mail: [email protected] Phone: 800-374-9663, select option 1. X To find past articles: Search for previous articles, plan corrections, and article updates online at woodmagazine.com/index. X To order past articles and issues: For articles, search woodstore.net. For issues, visit woodmagazine.com/backissues. Our subscriber list is occasionally made available to carefully selected firms whose products may be of interest to you. If you prefer not to receive information from these companies by mail or by phone, please let us know. Send your request along with your mailing label to Magazine Customer Service, PO Box 37508, Boone, IA 50037-0508. © Copyright Meredith Corporation 2017. All rights reserved. Printed in the U.S.A. Meredith Corporation allows the purchaser of this magazine to photocopy the included patterns solely for personal use. Any other reproduction of these patterns is strictly prohibited.

woodmagazine.com

1

IN THIS ISSUE OF WOOD

®

JULY 2017 • IS SUE 247

PLANS 24 On the cover: Outfeed Table At the end of the day, stop, drop, and roll away this support system with storage. 30 Phone and Tablet Charging Station Corral cord clutter inside this elegant, easy-to-build accessory. 42 Icebox with a Secret This totally cool project hides huge storage inside its classically styled skin. 48 Army Artillery Toys Jeepers! Our Mil-spec series salutes the ground game with two tough toys.

TOOLS & TECHNIQUES 31 Make Your Own Plywood Don’t settle for home-center faces; add exotic veneer to beautify the beast. 36 Shop Test: Dust Collectors Forget specs: We measured airflow and filtration equally to level the playing field. 54 Plumb for Compressed Air Skip the trippin’ on air hoses when you scatter hookups around your shop. 59 Tools & Materials Bench grinders, a cordless trim router, and more.

DEPARTMENTS 1 Taking Measure Escape to the shop. 4 Wood-Wide Web 25 project plans for $25. Twice. 6 Sounding Board Your voice, your projects, your shop. 14 Ask WOOD Jig up to saw circles. 16 Shop Tips Double-dowel joints, and more. 72 What’s Ahead A sneak peek at your next WOOD.

42

54

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WOOD magazine July 2017

59 36

30

48 woodmagazine.com

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WOOD-WIDE WEB WOODMAGA ZINE.COM

25 SHOP

PLANS FOR

$25! This profusion of plans represents the potential for a complete shop facelift. Organize and overhaul your shop with plans for workcenters, machinery bases, tool organizers, and more. For a limited time, you can save nearly $170 when you purchase this hand-selected bundle. woodmagazine.com/ 25for25shop

25 OUTDOOR PLANS FOR

$25! 4

We’ve curated our top outdoor plans and packed them into one yard-transforming bundle. Save more than $230 on plans for shade-casting arbors, eye-catching planters, feet-easing seating, and more. For a limited time, reclaim your outdoors at woodmagazine.com/25for25outdoor.

Want to see more deals like this? Get them first by signing up for our weekly WOOD Store Deals newsletter at woodmagazine.com/ woodstoredeals.

WOOD magazine July 2017

SOUNDING BOARD YOUR VOICE

How do you figure? Many furniture projects in WOOD magazine use “figure-8” fasteners to attach the tabletop to the apron. But I can’t seem to find them at any home centers or hardware stores in my area. Where can I get them? O.J. Cain via e-mail

That fastener, sometimes called a “desktop fastener,” allows for seasonal wood movement, O.J. You may have to go to a mainline woodworking store, such as Rockler or Woodcraft, or find them online at woodmagazine.com/buyfigure8.

Rapping on wood

There’s gold in them thar back issues While reading issue 244 of WOOD® magazine (Dec/Jan 2016/2017), I was again reminded how it is the only woodworking publication that actually teaches you how to build things and provides detailed plans. (The 4-square Table and Chairs article is like having a coach by your side.) And it always has been. Case in point: The dust-collection hood we built for our radial-arm saw left a lot to be desired— because it also left a lot of dust everywhere—especially when pivoted off a 90° cut. In search of a better solution, I spent many hours on the internet Googling and searching YouTube and found only bigger, more cumbersome boxes. Coming up empty there, I went old-school, manually searching through my old copies of WOOD. That’s when I found issue 43 (June 1991) with its dust-collection box for a radial-arm saw: a louvered box that you pin behind the blade oriented at the angle of the cut. Elegant and brilliant!

While attending the International Builders Show, WOOD’s Daniel Wells had his photo taken with rapper-turned-DIY-TV-host Vanilla Ice (below). So we asked our Facebook and Twitter followers to come up with a good rap name for a woodworker. Here are some of our favorite responses: Leonardo Murphy Busta Knuckle Gareth Glenn 50 Centimeters William Head Chisel in da Dizzle John Connor Flava Lathe Victor LaDonna Kinnick Sir Sawzalot James Cook Dust Collecta Eddy Harrell Little Piney Daniel Przybylski Eight Penny

—Pamela Peerce-Landers Sanatoga, Pa.

You’re making us blush, Pamela! Our online article index at woodmagazine.com/index would have found that article for you quickly (just search for “radial arm saw”). For readers who don’t have that issue, we’ve added the free plan to our website; find it at woodmagazine.com/RASDC.

Matt knows beans Matt Seiler’s article “Beans of Wisdom” in WOOD issue 244 was spot-on. I’m now looking for a group of fellow scrap hoarders so that we can sit in a circle and talk about our affliction. I’ll stand up and say, “I’m Chris, and I’m a wood-scrap hoarder.” Chris Stasny via e-mail 6

continued on page 8

Connect with us facebook.com/ woodmagazine

twitter.com/ WOOD_magazine

pinterest.com/ woodmagazine

instagram.com/ woodmagazine

E-mail [email protected]; or write to WOOD magazine, 1716 Locust St., LS-253, Des Moines, IA 50309; or call 800-374-9663, option 2. WOOD magazine July 2017

SOUNDING BOARD YOUR PROJECTS

Don Glencross, of Maynard, Mass.,

Pete Jacobs, of Yorktown, Va., made a playful version of our Hidden-hook Coat Rack in issue 240 (July 2016) as a gift for his musically inclined daughter. Pickling stain colors the white keys; ebony stain keeps the black keys looking sharp.

What to do with your leftover wood scraps? When they’re from a garapa (Brazilian ash) deck, you turn them into a matching patio table, as Ken Cook, of East Longmeadow, Mass., did.

Unwilling to settle for an off-the-shelf carrier for his three-wheel Catrike, Bart Schmidt, of Loudon, Tenn., crafted his own from maple, red oak, and birch plywood.

8

continued on page 10

WOOD magazine July 2017

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SOUNDING BOARD

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YOUR PROJECTS

Finishing Answers

Instead of pine, as called for in the plans for this Chairside Chest in issue 229 (November 2014), Randy Webb, of Martinsville, Ind., chose curly maple, making the project both simple and elegant.

Each issue, the finishing experts at Varathane anwer your staining and finishing questions.

Question: How do I stain a large table top and get consistent color across the entire surface? —Daniel W. - Belton, MO

For this Greene-and-Greene-style clock from issue 201 (November 2010), Bob Wolak, of Salisbury, Md., replaced the ceramic tile with a marquetry panel he created. The clock body is sapele finished with clear shellac.

Answer: Staining a large surface is different than staining a small surface. You need to work a little more quickly when staining a table top to achieve desirable results. Quickly and evenly apply a generous coat of Varathane Premium Fast Dry Wood Stain over the entire area and let it set for a couple of minutes. Then quickly wipe away all excess with consistent, medium pressure.

Jeff Kunde, of Kenwood, Calif., transformed a load of old Douglas fir 4×4s harvested from a wine cave into this inviting arbor. He bulked up the posts and beams by binding four of them together with steel strapping.

This one step process will allow the product to dry    ϐ ϐ Ǥ

Send us a photo of your work Want to see your work showcased in WOOD® magazine? Send a high-resolution digital photo of your completed project to [email protected].

ϐnishing tips, visit: www.varathanemasters.com 10

WOOD magazine July 2017

SOUNDING BOARD YOUR SHOP

Mini-split heat pump

32' Mortiser

Clamp racks Storage

Dust collector

Planer Spindle sander

Mitersaw Belt sander Dust port

Workbench

Sheet storage

Drum sander

Scrollsaw

Can wall

Finish and glue storage

Small parts

Dust port Trash can 24'

Bandsaw Tool tower

Router table

Tool boxes

Air compressor Shop Hanging storage vacuum Cutoff Hanging storage storage Bench/ Grinder storage

Small-part lumber rack

Y

ou could say that Pete Lynah has had sawdust in his shoes since age 10 when his dad gave him and his brother a 50-lb keg of 6d common nails for Christmas. He’s since moved on from hammering together tree forts and go-karts to building small exotic-wood boxes, oval Shaker boxes, corner cabinets, dining tables, and cedarlined hope chests for his daughters. He built 12

Storage

Tablesaw

Alcove

Outfeed table Dust port Shelves

Lean-to

Lumber rack

Tool boxes Stereo Storage

his first workshop more than 35 years ago, and after retiring he decided it was time for a shop upgrade. So he built a new one— essentially an upsize version of his previous space, right down to the tool layout. Pete framed, wired, and insulated a new 24×32' metal-clad pole building. The 3⁄4" plywood floor rests on pressure-treated 2×6 joists over a concrete slab. The joists provide

room for 5" metal dust-collection ductwork under the floor, running to a sealed room where his 2-hp dust collector resides, vented outside via three dryer vents. The ductwork leads to ports at his tablesaw, mitersaw, and by two benches. A shop vacuum services his smaller tools. A mini-split heat pump regulates temperature year-round. During extended WOOD magazine July 2017

A retired environmental science teacher, Pete felt compelled to install a 5kW solar array on the south-facing roof of the shop. The electricity it generates is subtracted from his utility bill. During summer months, the solar system produces more power than the shop consumes. The lean-to provides lumber storage.

South-facing double doors provide natural light and make easy work of moving materials and projects in and out.

time out of the shop in cold weather, Pete shuts off the mini-split, and a separate room with baseboard heat keeps finishes and glue from freezing. Pete built in loads of storage. A walled-off alcove in the back of the shop houses shelves for miscellaneous items. At the opposite end of the shop, Pete built wall racks for his raw lumber, sheet goods, and cut-offs. He organizes hardware and fasteners for woodworking and household maintenance in metal cans of all shapes and sizes, then arranges them on his “can wall.” A 200-amp breaker panel provides electric service for six 20-amp, 120V receptacle circuits, two 15-amp lighting circuits, and four 240V circuits to supply his tablesaw, dust collector, and baseboard heater. woodmagazine.com

In an alcove, a “tool tower” on the right stores portable power tools in their original cases. The machinist’s chests and stationary drawers next to it hold small tools such as screwdrivers, files, chisels, and sharpening equipment, as well as mechanics tools, including sockets and wrenches.

Show us your shop Send high-resolution digital photos of your shop to woodmail@ woodmagazine.com and we may showcase it in the magazine! 13

ASK WOOD

YOUR QUESTIONS

Starter hole ¼" hardboard

Elevate the workpiece on a 4×4 to provide clearance for the blade, and rotate the panel as needed. Cutting slowly reduces blade flexing and gives the best finished edge.

Q A

Have a question? Drop us an e-mail. askwood@ woodmagazine.com 14

Jig up a jigsaw for circles I don’t have a bandsaw or router, but need to cut a circular tabletop. Can I outfit my jigsaw with a trammel to do the job?

and circle meet. When you put the saw in place, the blade must rest snugly against the edge of the workpiece (or the flat edge of the hole) without deflection.

—Brian Davis, Normal, Ill.

Although a jigsaw wouldn’t be our first choice for cutting circles, Brian, it can be done. Begin by making an auxiliary base from 1⁄4" hardboard. Align the edge of the saw’s foot with one end of the hardboard and cut a slot for the blade. (We got good results cutting circles with a 10-tooth-perinch blade.) Then attach the saw with screws, if your base has them, or double-faced tape if it doesn’t. Mark a line on the bottom face of the base parallel to the edge and aligned with the blade teeth. Measure from the inside edge of the blade and mark your desired radius along the line. Drill a hole for a finish nail at this point, and at the centerpoint of the circle on your workpiece. When marking the centerpoint, either measure from the workpiece edge, or drill a blade starter hole tangent to the edge of the circle and chisel a flat surface where the hole

s of cir Radiu

cle

An auxiliary base eliminates tear-out and also reduces lateral blade movement. You may need screws longer than the stock screws to attach the auxiliary base. WOOD magazine July 2017

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SHOP TIPS

WORK FASTER, SMARTER, SAFER

Hollow a dowel for eye-popping joints I always look for ways to add interesting details to boxes, so I developed a means of hollowing a dowel to create a “double dowel” joint reinforcement, as shown right. To do the same you’ll need a doweling jig with replaceable inserts of various diameters. I use a Dowelmax jig (dowelmax.com). First, make a disposable wood fixture to hold the dowels for hollowing by placing 3⁄8" drill guides in the jig and drill 11⁄2" deep into the end of a scrap board. Then add a drop of

Tips earn up to $150. If your tip is the best of the issue, it wins Top Shop Tip honors, and you receive a

tool prize worth

cyanoacrylate glue to one end only of dowels 11 Next, place 1 redrill the holes with a 1 board about 11⁄4" from the end. Use a dowel to push out the hollow dowels.

3

3

or aluminum rod, or epoxy.

For sending this issue’s Top Shop Tip, Jeff receives a Turncrafter Commander midi lathe from Penn State Industries worth $370.

at least $300.

Send your tip, photos or drawings, and contact info to

[email protected] Because we try to publish original tips, please send yours only to WOOD magazine. ®

16

WOOD magazine July 2017

continued on page 18

EXTERIOR COATED SCREWS

MADE TO LAST WITH ULTR A GUARD COATING - THE INDUSTRY LEADING BR AND IN OUTDOO R C O R R O S I ON P R EV ENTI O N OUR SCREW COATING’S CORROSION RESISTANCE IS TESTED USING A SALT SPRAY TEST.

ZINC PLATED

THE SCREW IS CONTINUOUSLY SPRAYED WITH SALT WATER AND OBSERVED UNTIL THE SCREW SHOWS THE FIRST SIGN OF RED RUST CORROSION.

vs.

THE MORE HOURS THE SCREW LASTS DURING THE TEST, THE MORE YEARS IT WILL LAST UNDER NORMAL, REAL-WORLD APPLICATIONS.

ULTRA GUARD

36 hrs

3000 hrs

SHOP ONLINE www.quickscrews.com 800.743.6916

SHOP TIPS Quick-change, rock-solid drill-press table I drill wood and metal at my drill press, so I needed a way to quickly remove and reinstall the large-surface table that serves woodworking purposes. A pair of hold-down toggle clamps provide the solution shown. You’ll find them available from woodworking suppliers. —Les Beeckman, Saginaw, Mich.

Cleats

Make your own rounded plugs For convenience, cost-savings, and the ability to utilize uncommon wood species, I like to make my own button plugs. I simply chuck a dowel into a drill, place a small square of abrasive on an anti-fatigue floor mat, and sand the dowel end to the shape of an M&M candy, as shown. Don’t press down— allow the weight of the drill to do the work. Start with a coarse abrasive and work your way up to 220 grit. Cut off the button at your bandsaw. You can also make small square buttons so long as your drill chuck is large enough to hold square stock. —Tony Rush, Springfield, Ore.

18

continued on page 20

WOOD magazine July 2017

SHOP TIPS A bandsaw benefits from a sliding table, too Anytime I need to crosscut a short length of wood, such as a pen blank, I turn to the bandsaw for safe and controllable sawing, free of flying offcuts. To ensure a cut that’s square as well, I made a simple crosscut sled. It consists of three pieces of wood—one sized to slide snugly in the saw’s miter slot—joined squarely together. —Jim Judge, Casper, Wyo.

20

WOOD magazine July 2017

Sharpening tools or general grinding work is made a bit easier and more exact with RIKON’s low speed 1,750 RPM JULQGHUVDQGEXHUV

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Revolver Pen Kits NEW! These nostalgically stylish pens look and work just like a real revolver. When you press the click mechanism the pen tip extends, the trigger clip moves up and the 6-barrel cylinder rotates to replicate you loading the gun. Then, when you pull the hairpin trigger pen clip the tip retracts while the 6-barrel cylinder quickly spins

to replicate you firing the gun. Right above the cylinder you’ll find a black metal grip that mimics a revolver handle. And the bullet cartridge pen tip represents your favorite revolver bullet. Requires a pen making mandrel, bushings (Item # PKREVBU $5.95) and 3/8” drill bit (Item # PK10-10 $3.95). Patent pending.

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Fig.1 6 Barrel Revolving cylinder Fig.2 Trigger

Fig.3 Grip

Press

Pull

Spin

5HıOOH[WHQGVDQG 5HıOOUHWUDFWVDQG &\OLQGHUVSLQVZKHQSHQ F\OLQGHUVSLQV H[WHQGVDQGUHWUDFWV F\OLQGHUVSLQV

Fig.5 Gun Barrel

Bolt action handle smoothly advances and retracts the refill

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Antique Brass

Antique Pewter

20" W × 421⁄2" D × 341⁄2" H

D I M E N S I O N S :

Every shop needs a good support system

24

Approximate materials cost:

$225 11⁄2 1

sheets of 3⁄4" plywood and

sheet of

3⁄4" MDF

WOOD magazine July 2017

L

M I

41"

M

18½"

42½"

L

EXPLODED VIEW

18½"

Folding leg brackets secure legs in position.

3/8" washers and lock nuts Stash cutoffs inside.

#8 x 1½" F.H. screw

3/8" carriage bolt 3" long

4" locking swivel caster 42" ¼ x 1½" bolt

D

20"

#8 x 1½" F.H. screw

Lag bolts serve as leg levelers.

4" casters roll easily on any shop floor.

T

o improve safety and cut quality, workpieces should be well-supported as you feed them off a tablesaw. This fixture provides ample support, even for a full sheet of plywood, without taking over your shop. A flip-up wing provides a whopping 441⁄2×421⁄2" surface when needed, then folds down to a compact 20×421⁄2" footprint. The table even provides storage for lumber cutoffs. And for ultimate versatility, casters allow you to roll it out of the way or to another spot in the shop to use as a standalone table. The height of your saw may differ from ours (35"), so adjust the lengths of parts A, C, E, and F if needed to place the tabletop 1⁄8" lower than the saw table. Have your casters in hand before beginning, as their height affects the height of the table as well.

woodmagazine.com

25

B

E C

A

B

Butt the square end of a pivot arm against the case and align the arm’s edge with the top of the case. Drill a 3⁄8" hole through the arm and rib.

The case comes first fLearn to cut perfectly sized dadoes on the tablesaw. woodmagazine.com/ perfectdadovid

1 2

Cut the case sides (A), shelves, (B), ribs (C), and base (D) to size [Materials List, Cutting Diagram]. Rabbet and dado the case sides [Drawing 1]. Dry-fit the sides and shelves, and drill pilot holes into the shelves. Disassemble the parts and drill pilot holes through the uppermost shelf for attaching the top (I) later. Apply a finish to the interior faces of these pieces [Skill Builder, next page]. After the finish dries, glue and screw together the case sides, shelves, ribs, and base [Exploded View]. Apply finish to the exterior.

3

To create a pivot point, fill the hole with a length of 5⁄16"-square stock. Mark lines from corner to corner to find the center of the square. Then mark the 11⁄4" radius.

4

Flip the case upside-down and install the casters flush with the ends and edges of the base [Exploded View, Sources].

Now, just wing it

1 2

Laminate plywood for the pivot arms (E) and legs (F) 2" longer than listed [Drawings 2, 2a]. Square up one end of the laminations. Clamp each pivot arm (E) to a case rib (C) and drill the pivot holes [Drawing 1, Photo A]. Then mark the radius [Photo B] and cut and sand it to shape. Crosscut the pivot arms to length, and bevel the ends [Drawing 2a]. Bolt the arms

3

C 3/32" pilot holes

1 CASE

B

C

67/8"

B

77/8"

B

A

87/8"

B ¾" dado ¼" deep

C

13" ¾" rabbet ¼" deep

26

WOOD magazine July 2017

SKILL BUILDER Apply a durable finish fast Shop projects provide a perfect opportunity to practice new techniques. An outfeed table may not require a furniture-grade finish, but it does need a durable one. Here’s a finish that provides both looks and durability. You may find you like this technique well enough to use it on furniture, cabinets, and keepsake boxes. After sanding to 180 grit, brush on a coat of dewaxed shellac to add amber color and protect the plywood from the grain-raising effects of water-based polyurethane. After the shellac dries, spray or brush on three coats of polyurethane, buffing lightly between coats with a 320-grit sanding sponge.

fThe arm braces are made from MDF so the combined thickness of the braces and the wing top (H) matches that of the case top (I).

J

in place temporarily and check that they swing freely and clear the caster bolts. Cut the arm braces (G) and glue and screw them to the pivot arms [Drawing 2]. Attach this assembly to the case ribs and, with the arms up and flush with the top of the case, measure from the underside of a brace to the floor. Cut the legs (F) 1⁄2" shorter than this dimension. Attach the folding leg brackets [Sources] to the legs [Photo C] and then to the outer arm brace (G) [Photos D, E]. Remove the folding leg brackets, and apply finish to the wing and legs. Then bolt the pivot arms to the case ribs (C). Drill a hole centered in the bottom of each leg and install a 1⁄2×2" lag screw to serve as a leveler.

4

5 6

F

Release tab

C

Align the folding leg bracket flush with the end of the leg. Make sure the release tab has room to operate; then, screw the bracket in place.

F

Outer folding leg bracket F

G

D

Inner folding leg bracket

E

G

¼"

Release tab

Fold the legs to check for clearance and access to the release tabs before screwing the brackets in place. Position the inner bracket flush with the inside edge of the brace (G). The outer bracket sits in 1⁄4" so the release tab sits flush with, or just inside, the outer edge of the brace. woodmagazine.com

27

Top it off

1 2

3⁄4"

Cut MDF to size for the top panels (H, I) and laminate the case top [Exploded View]. Cut the trim pieces (J–M) to fit around each top panel (H, I) and glue them in place [Exploded View, Drawing 2].

3

Apply a finish to each top assembly. Screw the tops in place [Shop Tip, below left] after the finish dries and your outfeed is ready to provide support.

E

SHOP TIP

Produced by Craig Ruegsegger with Joshua Steele Project design: John Olson Illustrations: Roxanne LeMoine, Lorna Johnson

Cutting Diagram

E

F

Installing screws in tight spaces Most drill/drivers won’t fit inside the case to screw the case top in place, especially when you add the length of a bit with a screw balanced on its tip. For tight spots like this, chuck a right-angle adapter in your drill. Purchase an adapter at woodmagazine.com/drill90. A

B

A

B

B

¾ x 48 x 96" Plywood F

Materials List FINISHED SIZE

Part

T

W

L

A

case sides

3⁄4"

42"

265⁄8"

Matl. Qty. Ply

2

B

case shelves

3⁄4"

42"

13"

Ply

4

C

case ribs

3⁄4"

265⁄8"

3"

Ply

4

D

base

3⁄4"

42"

20"

Ply

1

E* pivot arms

11⁄2" 21⁄2" 25 7⁄8"

LPly

2

F* legs

11⁄2"

32"

LPly

2

11⁄2"

G

arm braces

3⁄4"

4"

41"

MDF

3

H

wing top

3⁄4"

23"

41"

MDF

1

case top 11⁄2" 181⁄2" 41" LMDF wing-top front/back 3 P J trim ⁄4" 11⁄2" 23" 3 1 1 P K wing-top side trim ⁄4" 1 ⁄2" 42 ⁄2" case-top front/back 3 1 1 P L trim ⁄4" 1 ⁄2" 18 ⁄2" 3⁄4" 1 1⁄ 2" P M case-top side trim 42 1⁄2" *Parts initially cut oversize. See the instructions.

1

I

D

C

C

¾ x 48 x 48" Plywood

2

G

2

G

2

G

I

2

Materials key: Ply–plywood, LPly–laminated plywood, MDF– medium-density fiberboard, LMDF–laminated MDF, P–pine. Supplies: #8×11⁄4" flathead wood screws, #8×11⁄2" flathead wood screws, 1⁄4-20×11⁄2" hexhead bolts (16), 1⁄4" washers (16), 1⁄4-20 nuts (16), 3⁄8-16×3" carriage bolts (2), 3⁄8" washers (2), 3⁄8-16 lock nuts (2), 1⁄2×2" lag screws (2). Blade: Dado set. Sources: Cart-King swivel lock 350-lb. casters (2), no. 2370T85, $24.16 ea.; Cart-King rigid 350-lb. casters (2), no. 2370T62, $12.04 ea., McMaster-Carr, mcmaster.com. Posi-lock folding leg bracket, no. 32754, $10/pair, Rockler, 800-279-4441, rockler.com. 28

B

I

H ¾ x 49 x 97" Medium-density fiberboard

J K

J

M

L

L

¾ x 5½ x 96" Pine WOOD magazine July 2017

Charging Station Take charge of your mobile devices and confine the clutter of cords.

13" W × 85⁄16" D × 6" H

D I M E N S I O N S :

The middle divider hides excess cable length and a power strip that provides plenty of places to plug in your devices.

30

Charge up to

6

devices at once using only

1

Note: Sizes of power strips vary, so have yours in hand before beginning construction and adjust dimensions if needed. (This compact model has three AC outlets and three USB ports: woodmagazine.com/powerstrip.)

outlet

WOOD magazine July 2017

Middle divider supports tablets.

EXPLODED VIEW

E D 1"

Slots organize charger and power cables.

C 1¼"

3/8"

15° bevel

B 1¼" 15° bevel ¼" round-over

3"

Apply veneer to complement your decor.

Tilted shelf keeps electronics upright.

A ¼" round-over 1/8" dowel 1" long

Start with the sides

1

Following the Full-size Pattern [page 33], mark out two sides (A) on a 51⁄4×8" blank of void-free 1⁄2" plywood [Skill Builder]. Bandsaw the sides, staying just outside the lines.

2

Stick the sides together with double-faced tape and sand to final shape. Separate the sides and mark their best faces as the outside faces.

SKILL BUILDER Build your own plywood To get 1⁄2" plywood with attractive edges for the sides (A) and shelf (B), glue up two layers of 1⁄4" Baltic birch plywood. You can leave the plywood natural, or veneer the faces. (We used walnut.)

Cauls

Caul Veneer

¼" plywood Cut two pieces of plywood and two of veneer, each 1⁄4" wider and longer than the finished part. For cauls, tape waxed paper to two pieces of 3⁄4" MDF 1⁄2" larger than the plywood. woodmagazine.com

Laminate the two pieces of plywood, keeping their ends and edges flush. Apply an even coat of glue to each face in turn and align the veneer flush with the edges and ends.

Clamp the assembly between the cauls to distribute pressure. Allow the glue to dry overnight, then trim the ends and edges of the blank. 31

A D

A

B

Keep the sides in place while routing by placing them on a piece of shelf liner. Hang a small area of the side over the bench to provide bit clearance, rout that area, then reposition the side to continue.

3

Tip! Position the slot in the rear divider where it best accommodates the power-strip cord.

Cut the shelf (B) to size [Materials List]. Round over the front edge of the shelf and outside edges (but not the bottom) of the sides (A) [Exploded View, Photo A]. Cut the dividers (C, D, E) to size [Drawing 1], beveling the bottom edges of parts D and E. Mark and cut the cord slots [Photo B]. File and sand radii on the corners of the slots and top corners of the dividers [Drawing 1, Photo C].

Raise your tablesaw blade fully to cut a nearly flat-bottom slot. Bump the saw’s stop switch with your leg and wait for the blade to stop before removing the divider.

1 DIVIDERS

4 5

C Round the bottom of each slot with a round chainsaw file. Use a flat file to radius the outside corners of the dividers and slots. 32

WOOD magazine July 2017

D

FULL-SIZE PATTERN C B

A

D With the wedges flush with the ends of the sides (A), apply glue to the shelf ends, rest the shelf on the wedges, and clamp. Remove the wedges before the glue sets.

Put it together

1

Tip! Use the waste area of the Full-size Pattern to size the wedges.

Glue the front divider (C) to the shelf [Exploded View]. Add the middle divider (D) after the glue dries. Cut two 15° wedges from 1⁄4" scrap. Cut away the narrow ends so the remaining wedges support the shelf with the middle divider resting on the bench [Photo D]. Cut a spacer 1⁄16" wider than your power strip and use it to position the rear divider (E) as you glue it in place. Drill holes into the dividers and shelf where shown on the Full-size Pattern. Glue in lengths of dowel, then sand them flush with the sides. Apply a finish. (We sprayed on satin-finish aerosol lacquer.) Install the power strip and your station is ready to charge into action.

2 3

Tip! Use a brad-point bit and sight the bit with the divider to drill straight.

fCan’t find 1⁄8" dowels

to match your veneer? Dunk bamboo skewers or birch dowels in stain, then touch up the ends after sanding them flush.

4

Materials List FINISHED SIZE

Part A* sides

T

W

L

1⁄ 2"

35⁄8"

8"

Matl. Qty. VP

2

B

shelf

1⁄ 2"

3"

12"

VP

1

C

front divider

1⁄4"

2"

12"

VP

1

D

middle divider

1⁄4"

61⁄4"

12"

VP

1

1⁄4"

31⁄4"

E rear divider 12" *Parts initially cut oversize. See the instructions. Materials key: VP-veneered plywood. Supplies: 1⁄8×12" walnut dowel. Bit: 1⁄4" round-over router bit.

VP

1

Produced by Craig Ruegsegger with John Olson Project design: John Olson Illustrations: Roxanne LeMoine, Lorna Johnson woodmagazine.com

33

Patent Pending

• Flint Fire Starter • Pen Clip Striker • Emergency Glass Breaker • Ball Point Pen

To order go to www.bereapenkits.com or call 1.877.736.5487

BereaHardwoods, Co. Inc. SINCE 1980

18745 Sheldon Rd • Middleburg Hts., OH 44130 • [email protected]

Berea Hardwoods, Co. Inc.

Move sheet goods with ease – even by yourself! If you’ve ever struggled to move a full sheet of plywood around your shop by yourself, our new Material Mate™ Panel Cart and Shop Stand is for you. This rock-solid steel cart has an expanding top frame that lies flat for loading and unloading and tilts to fit through a 30" wide door. Large casters roll over uneven terrain, then lock for stability. Add a top, and you can use it as a shop stand or outfeed cart. It’s another way we help you Create with Confidence! Material Mate™ (56889) $249.99 Sign up for our emails and get every day FREE SHIPPING! For details go to rcklr.co/228 or call 1-800-279-4441 and mention code 228 at checkout.

For a store near you or free catalog:

Materials code 228

SHOP TEST:

Dust Collectors Make one of these machines a priority for a cleaner shop and healthier you.

W

oodworkers often think of adding a dust collector only after purchasing their shop’s essential machinery. But we encourage you to consider new or upgraded dust collection now, regardless of your current tool lineup. Hooking up your dust- and chip-making machines to a collector reduces your time spent cleaning, as well as—hopefully—the amount of fine dust that lingers in the air before eventually settling. A fully ducted system with a large collector might be a luxury outside your budget. Fortunately, smaller, portable single-stage collectors can do the job well, and go easy on the wallet, too. These machines connect directly to a tablesaw, bandsaw, thickness planer, or other machine, typically with flex-hose. (See Stage Coach: Know the D.C. Difference, next page.) We tested eight single-stage dust collectors priced from $325 to $850, including one unit with both bag and canister filter options. Here’s what we found.

Airflow starts the process... The volume of airflow generated by a dust collector is expressed in cubic feet per minute (cfm), the industry specification for measuring a collector’s ability to gather debris. Meanwhile, resistance against airflow is measured in inches of static-pressure loss (sp). As you add more resistance (ribbed

36

WOOD magazine July 2017

Stage Coach: Know the D.C. Difference Single-stage dust collector Motor

These collectors draw debris directly into the impeller (fan), which blows it into the adjacent filter/collection cylinder. The heavier chips and dust settle into the collection bag, while the finer dust rises to the filter media (bag or canister) above, where it either gets trapped or, worst case, passes through the filter and returns to the shop air.

Impeller

Filter bag Cyclone chamber

Two-stage cyclone dust collector

Impeller Chip-collection bag

Canister filter

Chip-collection bin

Whether portable or stationary, these machines suck dust into a separation chamber that tapers into a cone. The heavier chips and dust settle into the collection bin below, while the finer dust gets sucked into the impeller above, and then blown into the filter. The primary benefit with a cyclone is that most debris never reaches the fan or filter.

flex-hose, elbows, reducers, etc.), you reduce the airflow through the duct, and thus, the collector’s ability to efficiently move debris. Using a pitot tube, manometer, and smooth-wall metal duct, we measured each collector’s maximum cfm performance at various levels of static-pressure loss. Using that information, we generated fan curves for each unit. Download our fan curve chart at woodmagazine.com/dcfancurves. Although a fan curve provides important data, it’s hard to translate that information into performance in the shop. So, we also used a 10' length of 4" flex-hose to hook each collector to a tablesaw, bandsaw, planer, and drum sander to gauge their effectiveness in actual-use scenarios. Six of the eight models have 6" inlets—the Rikon 60-150 and Supermax 821200 have 5" inlets—but all come with a 4" wye, letting you more easily connect to the 4" ports common to most woodworking machines.

woodmagazine.com

37

Dust buildup diminishes airflow 450

255

Airflow with cleaned seasoned filters

176

216

231

283

315

247

200

282

402

391 260

250

259

300

350 320

350

371 336

Cubic feet per minute (cfm)

400

150 100

Airflow with dust-laden filters after sanding 76 square feet of MDF Airflow measured at end of a 10' flex-hose connection to a 4" wye.

50 0

K AL 1 Z2 85 50 00 -C CK 5M 1 8 6 N 2 X 1 1 2 X V IO F M TX 60 W 82 10 0V 00 X AT AC N 00 0 X Y 1 3 L N 1 O 1 O A 1 F 1 R 05 Z K P IZ CRI RM TE 0-1 DC PM R O E D N T I 1 P G IC T SH JE JE SU AL AT R M E ER EN W G PO

As you can see in the airflow chart above, collectors perform disparately in the same woodworking scenario (collecting dust from a drum sander, in this case). The Powermatic PM1300TX-CK and Jet DC-1100VX-CK maintained most of their cfm as dust built up in their canister filters. Conversely, the Supermax 821200, Shop Fox W1685, and General International 10-105ACF M1 dropped off substantially with dust buildup. With these three machines, it’s important to knock dust from the filter media more frequently to maintain adequate airflow.

Generally, it takes at least 400 cfm to keep dust and chips suspended in ductwork. We found lesser numbers workable, but only in 10' or less of duct. Follow these best practices to maximize airflow: XFlex-hose quickly robs a collector of cfm, so use segments as short as possible. Actual cfm numbers with even a short piece of flex-hose measured about onehalf to one-third of the ratings specified by manufacturers. XIf using two runs of flex-hose on the wye, install a blast gate on each line so you can

Diverter

A cone-shaped diverter inside the Jet and Powermatic collectors forces debris toward the outer rim as it enters the separation chamber, better slowing down and settling heavier particles into the collection bag, rather than clogging the filter. 38

Powermatic’s metal chute streamlines the path to the separation chamber for debris. We believe this helped this unit produce the highest airflow of the group.

The connector hose on some models adds resistance under pressure by forming a sharper bend. To maximize airflow, trim the hose as short as possible. WOOD magazine July 2017

1000

Fair

800

600 Good

JET DC-1100VX-5M GENERAL INTERNATIONAL 10-1051ACF M1 Canister RIKON 60-150 SHOP FOX W1685 GRIZZLY 1028Z2 SUPERMAX 821200 JET DC-1100VX-CK Canister POWERMATIC PM1300TX-CK Canister

400

Excellent

Particle Count / cu. ft. (>0.5 micron) x 100

1200

200

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Number of MDF panels sanded * (* 4 sq. ft. of MDF sanded with 80-grit drum sander)

shut down the one not in use to maximize airflow through the hose being used. XPlaner chips will more likely hang up in flex-hose than will dust with one of these collectors. If you notice this happening, shorten your hose or eliminate bends in it. XAs dust builds up and seasons the filter, cfm will drop. Even if you knock dust from the filter, it will never return to its out-ofthe-box airflow performance.

...and filtration completes it

fOne micron equals .001 millimeter. For comparison, human hair typically measures about 40–60 microns in diameter.

woodmagazine.com

Getting the debris to the collector is only half the battle. The other half—filtering out the fine dust and returning clean air to the shop—proves more challenging. Thankfully, nearly all dust collectors today come with a filter rated to trap most dust particles 5 microns or larger. Better still, six of the eight test models claim to trap nearly all particles as small as 1–2.5 microns. The most damaging particles are those smaller than 10 microns, because they stay suspended in the air longer, where you can inhale them. These tiny particles are also the most difficult for your lungs to expel. (See the chart on page 41 for each machine’s filter-efficiency rating.) To equally evaluate each collector’s filtering ability, we used a Dylos particulate meter to measure air quality before, during, and after each test. This sensitive meter detects particles as small as 0.5 micron. As you can see in the chart above, some machines fared better than others, with bag

filters generally outperforming canisters. The Jet DC-1100VX-5M, using a 5-micron bag filter, excelled by keeping the most fine dust trapped. The General International led all canister-filter models, finishing second only to the Jet DC-1100VX-5M. To be fair, all eight machines’ performance exceeds industrial regulatory standards established by the National Institute for Occupational Safety and Health (NIOSH). The buildup of a dust cake, shown below, helps all filters trap more dust, but at the expense of airflow. So, over time, you’ll have to get a feel for how your collector performs: As collection seems to drop off, clear some of the dust from the filter to improve airflow. We found that cleaning a canister filter reduced its filtering ability until a dust cake

fWant to test the air quality in your shop? Get the same particulate meter we used: Dylos DC1100 Pro, $260, 877-351-2730, dylosproducts.com.

Dust buildup helps trap dust, but lessens suction Better suction/ worse filtration

Thinner cake

Better filtration/ worse suction Filter medium

39

We prefer the hoop-style band that holds the collection bag tightly against the inside of the collector’s rim because it’s easy to remove and install, and doesn’t leak. This type is found on both Jets, Powermatic, and Supermax.

Four models use traditional band clamps that fit into a depression around the outer rim to secure the bag. Small clips hold the bag in place while you affix the clamp on the General International and Grizzly models. With the Rikon and Shop Fox models you must use tape to hold the bag initially.

built up again, but not as noticeably with bag filters. And lower airflow means more dust at the source will likely get into the shop’s air. We also discovered that each machine had small leaks where dust escaped, sometimes particles so tiny we couldn’t see them, but could feel the air movement. Before beginning our “official” testing, we sealed up leaks around metal seams and welds with silicone sealant or duct tape, and used adhesive-backed foam weather stripping to improve the seal around bag rims.

More factors to consider

XRemoving/installing bags. All eight machines use plastic collection bags. Although they’re meant to be disposable, they’re thick enough that you should be able to dump the debris and reuse them several times. Before removing a collection bag, knock dust loose from the filter bag (or turn the beater on a canister) to prevent big globs of dust falling out while you’re working on the lower bag. Filter or collection-bag clamps must hold securely in place while maintaining a tight seal against dust leaks. But these should also be user-friendly, and some simply are not. (See the chart on the next page.) The Jet and Powermatic machines use setscrews to hold their canisters tight to the rim, and interior hoops to hold the collection bags (top left). Other models use band clamps (top right) to hold their collection bags and filters in place. XDual positions. The Supermax collector, shown above right, differs from the others in that its impeller sits in the same housing that supports the bags. But empty bolt holes in our unit leaked air until we covered them with tape or plugged them with bolts. XPortability. All the collectors have four swiveling casters for mobility, but the sturdy Powermatic, with bolt-on handles, proved easiest to move around the shop. 40

By flipping the Supermax blower housing top for bottom, you can position the air inlet up or down to better suit the flex-hose or duct running to your machines.

XRemote control. Only the Powermatic comes with a remote control, letting you activate it without having to bend down and trigger the power switch. It’s an infrared model, so you have to point it directly at the machine to make it work. If you want a remote for the other models, you’ll have to buy an aftermarket remote control accessory ($50–$80) into which you plug your collector. XNoise. All the collectors measured between 73 and 82 decibels, below the level where NIOSH recommends you wear hearing protection. But with no other machine running, the constant droning of the collector might prove too annoying to just let it run when you’re in the shop. XWarranty. We always appreciate a lengthy warranty, but these dust collectors have few parts that can go bad (motor, impeller bearings). We’re not saying you should dismiss the warranty altogether, but don’t make it a huge part of your buying decision.

fRead reviews of other dust collectors and dust-collection accessories at woodmagazine.com/ toolreviews.

Produced by Bob Hunter with Tom Brumback Illustrations by Kurt Schultz and Tim Cahill WOOD magazine July 2017

Dishing the Dirt on Dust Collectors

MODEL

EASE OF CLEANING FILTER

EASE OF EMPTYING COLLECTION BAG

MOBILITY

HORSEPOWER RATING

FILTER TYPE (BAG, CANISTER)

RATED FILTER EFFICIENCY, MICRONS

OVERALL DIMENSIONS, INCHES (W x D x H)

STANDARD

OPTIONAL

NOISE LEVEL, DECIBELS

CORD LENGTH

WARRANTY, YEARS (3)

COUNTRY OF ASSEMBLY (4)

SELLING PRICE (5)

ACCESSORIES

FILTRATION EFFECTIVENESS

MOTOR

AIRFLOW

PERFORMANCE RATINGS (1)

CONTACT INFORMATION

GENERAL INTERNATIONAL 10-105ACF M1

C

A

A

B

A-

1.5 14.3 12¾ 6

C

1

38×21½×71

3 plastic bags

Radio-frequency remote control, duct fittings, .3-micron HEPA filter

76

6'

L

T

$680

888-949-1161 general.ca

GRIZZLY G1028Z2

C+

B+

B

B

A-

1.5

B

2.5

37×22×77

1 plastic bag

Duct fittings, radio-frequency remote control

74

6'

1

T

$335

800-523-4777 grizzly.com

JET DC-1100VX-5M

B+

A

B

A

A-

1.5 11.6 11

6

B

5

38½×22×79

5 plastic bags

Radio-frequency remote control

74

6'

5

T

$550

JET DC-1100VX-CK

A

C

A

A

A-

1.5 11.6 11

6

C

2

38½×22×69

5 plastic bags

Radio-frequency remote control

75

6'

5

T

$700

POWERMATIC PM1300TX-CK

A

C-

A

A

A

1.75 14

12

6

C

2

39×22×71

3 plastic bags, infrared remote control

Duct fittings

82

6'

5

T

$900

800-274-6848 powermatic.com

RIKON 60-150

C

A-

B

C

A-

1.5 11.8 10

5

B

5

36×22×78

1 plastic bag

73

6'

5

C

$380

877-884-5167 rikontools.com

SUPERMAX 821200

A-

B

B

A

A-

1.5 16.5 11½ 5

B

2.5

39×19×81

3 plastic bags, 4"x 6' flex-hose

75

8'

3

T

888-454-3401 $450 supermaxtools.com

SHOP FOX W1685

A-

A-

B

C

A-

1.5 15.5 12

B

2.5

38×22×77

1 plastic bag

INLET DIAMETER, INCHES (2)

MAXIMUM AMP DRAW (MEASURED)

SECONDARY

IMPELLER FAN DIAMETER, INCHES

PRIMARY

13 12¾ 6

800-274-6848 jettools.com

1.

A B C

Excellent 2. All units include a 4" plastic wye 3. (L) Lifetime, except for commercial Good applications Fair 4. (C) China (T) Taiwan 5. Prices current at time of article production and do not include shipping, where applicable.

2017

Duct fittings

81 8'6" 2

C $405

800-840-8420 shopfox.biz

Put your money where the dust doesn’t blow We placed a premium on filtration and airflow, and made the other characteristics of the dust collectors a lesser priority. Although we liked nearly everything about the Powermatic PM1300TX-CK, we can’t reward its ineffective filtering ability. So our Top Tool nod goes to the Jet DC-1100VX-5M ($550) and the Shop Fox W1685 ($405). These models best combined airflow with excellent filtration. Our Top Value award goes to the Grizzly G1028Z2. Selling for $70 less than the Shop Fox, it produced results nearly as good.

2017

WOOD Magazine

WOOD

TOP TOOL

TOP TOOL

Jet DC-1100VX-5M

Shop Fox W1685

®

Dust Collector

woodmagazine.com

6

®

Magazine

Dust Collector

WOOD

®

Magazine

Dust Collector

Grizzly G1028Z2

41

One cool chest of drawers

Icebox Redux It looks like an old-fashioned icebox, but instead of cubby-hole-size doors and a cramped interior, the entire front opens to reveal a bank of full-width drawers.

42

WOOD magazine July 2017

¼" round-over 42¼" ½" round-over

P

175/8"

19¾"

Q S #8 x 1¼" panhead screw

P

Mitered ends

G

R

O 41"

S J

EXPLODED VIEW

Double roller catch

K

11/8"

5/8" round-over with a 1/8" shoulder

M

N

#20 biscuit

177/8"

6"

38½"

Mitered ends

1 SIDE ASSEMBLY (Inside of right side shown) ¼" groove 3/8" deep

¾" rabbet 3/8" deep, cut after assembly 3/8" rabbets ¼" deep

C

B

421⁄4" W × 193⁄4" D × 40 5⁄8" H

D I M E N S I O N S :

127/8"

Approximate lumber cost:

$250 2 4 6.2 doors

drawers

cubic feet of storage

Note: The sides protrude beyond the carcase top and bottom (G) at the rear, creating a recess for the back. woodmagazine.com

E

nhance your vintage-style kitchen with this new take on a classic icebox. It’s equally at home in the dining room filled with table linens or in the bedroom cooling off some hot lingerie.

F

D 3/8" rabbets ¼" deep ¼" grooves 3/8" deep

F

1 2

¼" groove 3/8" deep

397/8"

Build the carcase Cut the carcase rails and stiles (A–E) to size [Materials List]. Groove the edges of each part to match the thickness of the side panels (F) [Drawing 1]. Rabbet the rail ends to form mating stub tenons. Cut and finish-sand the side panels (F). Glue and clamp one right-hand and one left-hand side. Cut the carcase top and bottom (G). Then rabbet and dado each side to match the thickness of the top and bottom.

A

¼" grooves 3/8" deep

6¾"

E 127/8" ¾" dado 3/8" deep, cut after assembly

41/8" 43

I H

1/16"

overhang

A Measure the carcase diagonals to check for square. Equal dimensions ensure a trouble-free assembly of the carcase and its adjoining parts.

B Glue and clamp the face frame to the carcase, flush at the top and with the stile edges equally overhanging the sides. The lower rail protrudes 1⁄8" above the carcase bottom (G).

I

K

J

Tip! It’s a good idea to dry-assemble your project as you complete the various parts and before you apply the finish. This way adjustments can be made without ruining the finish.

3

Drill holes and slots [Drawing 2] for attaching the top (Q) later. Glue up the carcase with the front edges of the top, bottom, and sides flush [Photo A]. Cut the face-frame stiles and rails (H, I) and pocket screw them together [Drawing 2]. Mount the face frame [Photo B]. Flushtrim and chamfer the stiles. Cut the liners (J) and spacers (K). Glue and clamp the spacers to the liners [Drawing 2]. Finish-sand the liners and install the liner/spacer assemblies [Photo C]. Cut the back (L), ensuring it fits between the sides and aligns flush with the outer faces of parts G at top and bottom. Set the back aside.

4 5 6

44

H

Tip! To ensure that the liner faces and stile edges align, place a liner against the inside of the carcase side and measure from the liner face to the stile edge. Cut the spacers (K) to this width.

C Glue and clamp the liner assemblies to the carcase with the liner front edges against the backs of the face-frame stiles (H). WOOD magazine July 2017

Note: With the top (Q) fixed at the front of the carcase, it can’t move. So continuously glue the crown front to both the top and the crown base front (O). The crown sides (S) must allow the top to move, so continuously glue the crown sides to the crown base sides (P) but apply glue only to the front 6" of the crown where it meets the top. Tip! Crown molding can be difficult to clamp, so use a 23-gauge pin nailer to hold it in place until the glue dries.

woodmagazine.com

Add the base and top

Make the drawers

1

1 2 3

Cut the base front and sides (M, N) to width, rout the round-over [Drawing 3], and miter-cut them to length [Exploded View]. Cut biscuit slots in the miter faces. Referring to Drawing 3, lay out the pattern on the base front, then jigsaw and sand it to shape. Glue and clamp the base front and sides to the carcase. Cut the crown base front and sides (O, P) to width and miter-cut them to length. Rout the round-overs [Drawing 4]. Glue and clamp the crown bases to the carcase [Exploded View]. Glue up a blank for the top (Q) and cut it to size. Finish-sand both faces and rout the profile on the ends and front [Drawing 4]. Install the top, flush with the rear edges of the sides and centered side-to-side, with screws (no glue) driven from inside the carcase [Exploded View]. Miter-cut the crown front and sides (R, S) to length [Exploded View]. (We purchased crown molding rather than making it ourselves.) Install the crowns.

2 3

Cut the drawer sides (T). Cut both the drawer fronts (U) and drawer backs (V) to the size listed for the drawer backs. Rout half-blind dovetails in the drawer parts [Drawing 5]. (We used a dovetail jig with 7⁄8" center-to-center pin spacing.) Lay out and jigsaw the ogee curve on one side [Drawing 5a] and sand it smooth. Use this side as a pattern to mark and shape the remaining sides. Dry-assemble one front and one side, mark the finished width on the front, and cut all the fronts to that width. Groove the drawer parts to accept the bottoms (W) [Drawing 5]. Cut the bottoms, finish-sand the parts, and assemble the drawers. Notch and drill holes for the drawer slides [Sources] in the backs (V) [Drawing 5b]. Set the drawers aside.

fLearn about using a dovetail jig. woodmagazine.com/ dovetailvid

4

4

45

J

11/8" CC 1/8"

CC

gap DD

DD

1/8"

gap

Spacer

D

F

Seat the stile (CC) and rail (DD) in the door rabbets and lightly clamp them in place. Apply bar clamps to eliminate gaps. Then tighten the initial clamps.

With the cabinet on its back, align the doors and install the hardware. Leave 1⁄8" gaps between the face frame and the ends of the center stile (CC) and mid rail (DD).

E 6 SMALL DOOR ASSEMBLY (Viewed from back)

8 DRAWER SLIDES

Rest the cabinet member of a drawer-slide on the spacer. Screw the slide to the liner (J). Repeat on the other side.

G

3/8" rabbet 3/8" deep routed after assembly Double roller catch strike

Rout ¼" round-over on outside edge of door after assembly.

3/8" rabbets ¼" deep Brass icebox hinge

Y

I

11½"

Y 14¼" CC

X

X

13½"

11½"

Y

BB

11½"

DD

221/8"

Brass icebox latch

Z

Brass icebox latch

29¾"

J

3/8" rabbet 3/8" deep routed after assembly

¼" grooves 3/8" deep

Rout ¼" round-over on outside edge of doors after assembly.

K

3/8" rabbets ¼" deep

NOTE: All dimensions from top face of G . Lowest slide rests on top face of G .

Z

30½" Brass icebox hinge

X X

7 LARGE DOOR (Viewed from back)

75/8"

¼" grooves 3/8" deep

G I

1

dry. Rabbet and round over all three doors where shown. Cut and finish-sand the center stile (CC) and mid rail (DD). Glue and clamp the small door assembly [Drawing 6, Photo D]. Cut and glue the catch block (EE), centered, to the upper face-frame rail (I) [Drawing 2].

2

Finish it up

Build the doors Cut the door stiles and rails (X–Z). Groove the stile and rail edges to match the thickness of the door panels (AA, BB) [Drawings 6 and 7]. Rabbet the ends of the rails to form mating stub tenons. Cut the small door panels (AA) and large door panel (BB) and finish-sand them. Glue and clamp the doors, check them for square, and place them on a flat surface to

1/8"

Y

Y

46

14¾"

H

3 4 1

Finish-sand where needed; then, apply a finish. (We stained everything but the WOOD magazine July 2017

3 4

Install the hinges, latches, nameplate, double roller catch, and catch strike [Exploded View, Photo F, Sources]. Stand the cabinet upright. Attach the front fixing clips to the drawers [Drawing 5]. Slide the drawers onto the drawer slides until the slides engage the fixing clips. Now start the negotiations on where to locate your versatile creation.

drawers with Varathane Golden Oak, let it dry for 48 hours, and then applied waterbased satin polyurethane to all parts.) Nail the back (L) to the carcase [Drawing 2]. Cut a 221⁄8"-tall scrapwood spacer and use it to position the upper drawer-slide cabinet members [Photo E, Sources]. Progressively trim the spacer [Drawing 8] and use it to install all but the lowest pair of drawer slides.

2

Produced by Kevin Boyle with Brian Bergstrom and Jan Svec Project design: Fran Skwira, Miramar, Fla. Illustrations: Roxanne LeMoine, Lorna Johnson

Cutting Diagram B

H

H

B

A ¾ x 7¼ x 96" Oak C

E

X

Y

Y

K

A

T

W

L

Matl.

Qty.

front stiles

3⁄4"

13⁄4"

397⁄8"

O

2

B

back stiles

3⁄4"

21⁄2"

397⁄8"

O

2

C

upper rails

3⁄4"

4"

127⁄8"

O

2

D

center rails

3⁄4"

21⁄2"

127⁄8"

O

2

E

lower rails

3⁄4"

4"

127⁄8"

O

2

127⁄8"

133⁄8"

OP

4

3⁄4"

16"

361⁄4"

BP

2

H

side panels carcase top and bottom face frame stiles

1⁄4"

3⁄4"

29⁄16"

397⁄8"

O

2

I

face frame rails

3⁄4"

3"

32"

O

2

J

liners

3⁄4"

16"

323⁄8"

BP

2

K

spacers

3⁄4"

1"

323⁄8"

O

4

back

1⁄4"

337⁄8"

351⁄2"

BP

1

Carcase A

G

K Z

Y

Y

Y

EE

¾ x 9¼ x 96" Oak Q

FINISHED SIZE

Part

F

Y

X

Materials List

Q

L

Base and top

¾ x 7¼ x 96" Oak Q

I

¾ x 7¼ x 96" Oak DD M

CC

D N

¾ x 9¼ x 96" Oak *P *P *O ¾ x 5½ x 48" Oak *T

D N

*T

M

base front

3⁄4"

6"

381⁄2"

O

1

N

base sides

3⁄4"

6"

177⁄8"

O

2

O

crown base front

1⁄ 2"

21⁄8"

38"

O

1

crown base sides

1⁄ 2"

21⁄8"

175⁄8"

O

2

Q

top

3⁄4"

193⁄4"

421⁄4"

EO

1

R

crown front

9⁄16"

21⁄4"

41"

OC

1

S

crown sides

9⁄16"

21⁄4"

191⁄8"

OC

2

P

* Plane or resaw to the thicknesses listed in the Materials List.

Drawers and doors

*V

¾ x 7¼ x 96" Maple (4 needed) R S 9/16 x 2¼ x 96" Oak crown molding

S

J

G

AA

BB

F

J

¾ x 48 x 96" Birch plywood

F

F

F

¼ x 48 x 96" Birch plywood

W

W

61⁄8"

147⁄8"

M

8

5⁄ 8"

43⁄8"

315⁄8"

M

4

backs

5⁄ 8"

61⁄4"

315⁄8"

M

4

W

bottoms

1⁄4"

307⁄8"

145⁄8"

BP

4

X

small door stiles

3⁄4"

21⁄4"

141⁄4"

O

4

Y

door rails

3⁄4"

21⁄4"

111⁄2"

O

6

Z

large door stiles

3⁄4"

21⁄4"

301⁄2"

O

2

AA small door panels

1⁄4"

111⁄2"

101⁄2"

OP

2

BB large door panel

1⁄4"

111⁄2"

263⁄4"

OP

1

CC center stile

3⁄4"

25⁄8"

293⁄4"

O

1

DD mid rail

3⁄4"

23⁄4"

141⁄2"

O

1

2"

O

1

3⁄4" EE catch block 21⁄4" *Part initially cut oversize. See the instructions.

¼ x 48 x 48" Oak plywood

L

5⁄ 8"

V

AA G

sides

U* fronts

T

*U

W

W

Materials key: O–oak, OP–oak plywood, BP–birch plywood, EO–edge-joined oak, OC–oak crown molding, M–maple. Supplies: 1" wire nails, 11⁄4" pocket screws (8), #20 biscuits (2), #8×11⁄4" panhead screws (6). Blade and bits: Dado set; 1⁄4", 1⁄2", and 5⁄8" round-over, bottombearing flush-trim, chamfer, 3⁄8" rabbet, and dovetail router bits. Sources: Drawer slides: Hettich Quadro IW21 soft-closing slides, 15", no. HT9134368, $24.05 per pair (4 pairs); Hettich Quadro front fixing clips for IW21, no. HT9140416, $1.76 per pair (4 pairs); double roller catch, no. SP2001, $1.07, Woodworker’s Hardware, 800-383-0130, wwhardware.com. Icebox hardware: Left-hand four-piece set (pair hinges, latch, strike), no. DL-B300-2L, $10 (2); right-hand four-piece set (pair hinges, latch, strike), no. DL-B300-2R, $10; icebox sign, no. I12-B329SB, $4; #7×5⁄8" brass-plated oval-head screws, no. SCR758OPHBP, $.75 pack of 25 (3 packs), D. Lawless Hardware, 618-395-3945, dlawlesshardware.com. woodmagazine.com

47

Mil-spec This nimble vehicle and light artillery piece performed with distinction in rugged terrain from WWII through Vietnam. They were cheap and quick-to-build back then, and these models retain those traits: you can build them from scrapwood in a weekend!

Note: To build this project, prepare 12"-long blanks in the following sizes: 1⁄8×3 1⁄4" maple, 3⁄16×1" maple, 1⁄4×3 1⁄4" maple, 1⁄4×3 1⁄4" cherry, 3⁄8×1" maple, 3⁄8×1" cherry, 1⁄2×1" cherry, 1×2 1⁄2" maple, 1 1⁄2×3" cherry.

Let’s start with the Jeep

1

Cut the frame (A) to the listed length [Materials List] but 25⁄16" wide. Rip a 3⁄16" strip from one edge, and from it crosscut two 2"-long pieces. Attach and trim those pieces [Drawing 1a, Photo A.] Then cut the back seat (B) to size and set aside [Drawing 1]. From a 11⁄2×3×12" cherry blank, saw a 1⁄2"-long piece from one end for the cowl (C). Cut and sand the 27° miters [Drawing 1b]. Then cut a 11⁄2×11⁄2×12" scrap and miter one end at 27°. Double-face-tape the cowl to the end of the scrap and rout the corners [Photo B].

A

2

1¾"

A Glue the crosscut edge pieces back onto the frame (A), aligning them as shown. After the glue dries, trim them flush with the end of the frame.

48

WOOD magazine July 2017

J E E P 3 3⁄ 4 " H × 3 1⁄ 2 " W × 7 3⁄ 1 6 " L 37mmGUN 3 1⁄ 4"H×3 5⁄ 8"W×9 1⁄ 8"L

D I M E N S I O N S

37mm Gun

647,925 Number of Jeeps manufactured for WWII

7'7"

Length of actual gun barrel

1a FRAME 23/8"

1¾"

3/16"

¼"

21/8"

1½"

E

3"

¾"

1 CHASSIS EXPLODED VIEW

3" 3/8"

7/32" hole

G

H

F

¼" round-overs

1b COWL 11/8"

COWL TOP VIEW

23/8" ½"

B 1"

D

G

1¾"

C

A

¼" 5/16"

I

23/8"

¼" round-over

¼"

1½"

7/8"

¼"

J

6¼"

A

¼" hole 3/8" deep (drill after assembly)

C ¼" round-overs

27°

C 3" COWL FRONT VIEW

7/32" hole ¾" deep

¼" ¼" washer

7/32" axle peg 11/8" long

1½" wooden wheel

woodmagazine.com

49

Scrap

C

C

B Rout 1⁄4” round-overs on the top edges of the cowl (C), aligning the mitered edge of the cowl flush with the edge of the scrap.

Two cuts create the fender wells. Make the first cut with the blade at 90°; for the second cut, angle the blade to 45°.

Tip! For round-overs smaller than 1⁄4", simply sand them. On small parts, such as the fuel can (K), seats (N), and windshield (O), hand-sanded round-overs look just fine.

3

Retrieve the 11⁄2" cherry blank and rip it to 21⁄2" wide. Attach a copy of the Hood Fullsize Pattern [page 53] to the end of the blank. With the blank on end, cut the kerfs for the hood (D). Cut the fender wells [Photo C], saw the hood to length, rout the top edges, and drill the headlights using a Forstner bit. Glue, align, and clamp the cowl (C) and hood (D). Then glue and clamp the C/D assembly to the frame (A) [Photo D]. Cut to size the floorboard (E), and dashboard (F) [Drawing 1]. Glue the dashboard to the cowl (C) flush side to side. Glue in the floorboard tight against the dashboard and centered side to side. Glue in the back seat (B) as shown in Drawing 1. Cut the rear quarterpanels (G), and end gate (H). Double-face-tape the panels face-to-face, attach a copy of the Rear Quarterpanel Full-size Pattern, and cut and sand to shape. Attach the panels and end gate to the chassis [Drawing 1] with the bottom edges of the panels flush with the bottom of the floorboard (E) and the top of the end gate flush with the top panel edges. Round over the ends of the panels.

4 5

Tip! Save tedious R=3/16"

sanding in tight spots by finish-sanding each part as you make it, prior to attaching it to other parts.

2a SEAT 104º

1¼"

6

N

¼"

1¼"

N

1/16" round-over

2 CHASSIS

O M

F E

N

7/32" hole ¾" deep 1½" wooden wheel

K M

L

7/32" axle peg 11/8" long, cut to 1" 3/32" hole 3/8" deep ¼" round-over

50

5/8" eye screw WOOD magazine July 2017

D

C

A

D

L

E

F

Attach the cowl/hood (C/D) to the frame (A), aligning the hood flush with the edges of the frame and set back 1⁄4” from the front end.

Drill the wheel-axle-peg holes 3⁄4" deep—the extra depth allows you to fine-tune the depth of the axle pegs later for wheels that spin freely, but without slop.

Cut the fenders to length using a bandsaw or scrollsaw. Go easy to avoid breaking the end-to-end glue joint.

7 8

6

Add the machine gun

In the floorboard (E) mark and drill the centered gun-turret hole [Drawing 1]. Cut the front wheel spacers (I) to size and glue them to the chassis [Drawing 1]. Mark and drill holes for the axle pegs [Photo E]. Also drill a 7⁄32" axle-peg hole 3⁄4" deep through the end gate (H).

A few more parts complete the Jeep

1

Cut the bumper (J) to size, and glue it to the front of the frame (A), centered side to side. Then, cut the fuel can (K) [Full-size Pattern] and glue it to the end gate (H), positioned as shown in Drawing 2. From your 1⁄8" maple blank, cut two 1⁄2×3" strips. Tilt your tablesaw blade to 24.5°, crosscut each strip at its center, and crosscut the offcut to make matching bevels [Fender Full-size Patterns]. Glue each pair back together at the beveled ends to form the fenders (L). Make a copy of the Driver-Side and PassengerSide Fender Full-size Patterns and adhere those to the tops of the fenders. Cut the fenders to length [Photo F]. Then sand each angled edge to match where it mates against the cowl. Take your time to ensure a tight fit. Glue on each fender, aligning it flush with the front of the hood and centered on the headlights. Cut the rear wheel wells (M) and glue them in place [Drawing 2]. From your 1⁄4" maple blank, cut two 11⁄4×25⁄8" pieces. Tilt your blade to 14°, crosscut each piece at its center, and glue each pair back together to make the seats (N) [Drawing 2a]. Sand the round-over. Glue the seats in place against the quarterpanels. Cut to size the windshield (O), round over one edge, and glue it in place [Exploded View].

Apply finish to the Jeep (we sprayed on three coats of aerosol lacquer). Also finish five wheels and axle pegs [Source], being careful to keep finish off the portion of the pegs that will be glued into the chassis. Glue on the wheels and axle pegs, using washers only on the four rotating wheels [Drawing 1]. The wheels should freely rotate without excess slop. Cut down the axle peg holding the spare tire. Spread open a 5⁄8” eye screw to make a tow hook and add it to the back of the Jeep, centered on the end of the frame (A) [Drawing 2].

7

Cut the machine gun (P) to size and shape [Full-size Pattern]. Drill holes for the gun barrel and stand. With a square, check that the gun is perfectly vertical before drilling the barrel hole. Cut the barrel, stand, gun grip (Q), and ammo box (R) to size [Drawing 3]. Assemble the machine gun. Apply finish and allow it to dry before gluing the stand into the hole in the floorboard (E).

2

5/8"

3 MACHINE GUN

2

3 4

1

3/8"

P

1/8" hole 3/8" deep, centered

Q

R

1/8" dowel 2½" long

Barrel

7/8"

5/8"

¾" ¼" hole ¼" deep on bottom face, ½" from front

¼" dowel 3" long

Tip! When drilling a hole Stand

in a small part such as the machine gun (P), hold the part steady in a wood hand-screw clamp and use a drill press.

5

woodmagazine.com

51

Materials List, Draw-

1⁄2" hole

] and complete the slot ]. Cut the tow bars (V) and tow-bar brackets (W) [Full-size Pattern]. Drill and shape them [Drawing 5]. Glue the tow-bar

3

]. Then drill angled the tow bars [Photo G]. Attach the tow bars to the brackets with screws and lock nuts. Cut the barrel mount (X) and bolt (Y) to size. Drill a hole into the end of each for the barrel and cradle dowels. Glue in the dowels, and then glue the barrel to the barrel mount [Drawing 4]. Glue this assembly to the axle. Cut the recoil guard (Z) to shape [Full-size Pattern], drill holes, remove the pattern, and glue it to the bolt (Y). Apply finish and add the wheels, axle pegs, and washers as you did for the Jeep. Your classic battlefield duo is ready for action!

Barrel ¼" dowel 5" long

Z

¼" hole ¼" deep

Y

4 37MM GUN

Cradle ¼" dowel 1½" long

½"

#6-32 machine screw ¾" long

4

T

5 6

X ¼" hole ½" deep

V

V

V

5/8" eye screw

1/16"

Lock nut

1/8"

S

W

7/32" hole ¼" deep

W 1/16"

U 1/16"

¼" washer 1½" wooden wheel

5 37MM GUN PARTS VIEWS 2¼"

R=1/8"

½" hole 5/8"

T

3/16"

1¼"

9/64" hole

¾"

V 11/8" UPPER SHIELD 52

7/32" axle peg 11/8" long

R=3/16"

G 3/8"

5" TOW BAR

¼"

Drill angled 1⁄16" pilot holes for 5⁄8" eye screws. Eyeball the angle so the eyes overlap when the angled edges of the tow bars meet, allowing the Jeep’s tow hook to fit through them. WOOD magazine July 2017

Materials List FINISHED SIZE

FINISHED SIZE

Part

T

W

L

Matl.

Qty.

B

back seat

23⁄8"

61⁄4"

M

1

S

axle

1" 23⁄8"

13⁄4"

M

1

T

upper shield

C

1

U

lower shield

C* cowl

3"

1⁄ 2"

D* hood

11⁄2"

21⁄2"

11⁄2"

C

1

V

tow bars

E

floorboard

1⁄4"

3"

21⁄8"

M

1

W

tow-bar brackets

F

dashboard

1⁄ 8"

11⁄2"

3"

M

1

X

barrel mount

1⁄4"

13⁄8"

41⁄4"

C

2

Y

bolt

" 11⁄8" 3" 3⁄4" I front wheel spacers 3⁄16" 3⁄4" 1 1 J front bumper ⁄4" ⁄4" 23⁄8" 3 K fuel can ⁄8" 7⁄8" 1 1⁄4" 1 L* fenders ⁄8" 1⁄2" 2"

C

1

M

2

M

1

M

1

H

M

rear quarterpanels

end gate

rear wheel wells

1⁄4

M

2

13⁄4"

C

2

1⁄4

M

2

1⁄ 8

M

1

C

1

M

1

C

1

1⁄4"

5⁄ 8"

Q

gun grip

" 11⁄4" 11⁄4" " 13⁄8" 3" 3⁄ 8" 3⁄ 8" 11⁄2" 1⁄ 8" 3⁄ 8" 5⁄ 8"

R

ammo box

1⁄4"

N* seats O

windshield

P* machine gun

woodmagazine.com

1⁄4"

11⁄2"

G

T

W

L

Matl.

Qty.

1⁄ 2

C

1

1⁄ 8

M

1

M

1

C

2

37mm gun

Jeep A* frame

Part

3⁄4"

5⁄ 8"

" 1⁄2" 21⁄2" " 11⁄4" 21⁄4" 1⁄ 8" 5⁄16" 21⁄4" 1⁄4" 3⁄ 8" 5" 1⁄4" 7⁄16" 3⁄4" 3⁄ 8" 3⁄ 8" 1" 3⁄ 8" 3⁄ 8" 1⁄ 2" 1⁄ 8" 1⁄ 2" 11⁄8"

M

2

C

1

C

1

M Z recoil guard *Parts initially cut under- or oversize. See the instructions.

1

Materials key: M–maple, C–cherry. Bits: 1⁄8", 3⁄16", and 1⁄4" round-over router bits; 3⁄8" Forstner bit. Source: Each kit includes the hardware and specialty parts to build one Jeep and one 37mm gun. You provide the lumber. 1⁄8" dowel rod 3" long, 1⁄4" dowel rod 10" long, 11⁄2" wooden wheels (7), 7⁄32" axle pegs (7), 1⁄4" galvanized washers (6), 5⁄8" eye screws (3), #6-32×3⁄4" machine screws (2), #6-32 lock nuts (2). Kit no. RS-01149, $5.95, 888-636-4478, woodmagazine.com/jeepkit.

Produced by Bill Krier with Kevin Boyle Project design: Kevin Boyle Illustrations: Roxanne LeMoine, Lorna Johnson 53

Plumb Your Shop for Air Build a network to put compressed air always within easy reach.

N

o matter the size of your shop, you’ll enjoy the benefits of having a piped network of compressed air. Rather than snaking a single long air hose around obstacles and trying not to trip over it, install your own custom system with hose connections right where you need them. You can then install shorter hoses and the tools you need at each station. Read on to learn the how-to as well as the why-to.

54

WOOD magazine July 2017

Select a strategy first Start by planning what you want to achieve with a system. Do you just need to blow dust off projects and use a brad nailer occasionally? Do you want to spray-finish projects? Or do you want to use other pneumatic tools, such as sanders or impact wrenches? Each need requires a different airflow volume, so choose an air compressor capable of supplying the needed cfm (cubic feet per minute) for the tools you plan to use. (See below.) In addition to airflow, your compressor needs sufficient tank size so its pump won’t run constantly. Next, lay out the locations of the compressor and hose connections. To cut down on noise, consider locating the compressor in a closet or adjacent room, and then run the pipe through the wall. But remember, a compressor needs fresh intake air, so make sure the location has adequate ventilation. Place hose-connection stations where you’ll use them most. For example, one near the workbench provides quick access for nailers, and another by the overhead garage door makes it easy to inflate a low tire on a vehicle parked outside. If you plan to spray finish, install a connection near an exhaust fan or overhead door.

Shut-off valve

Tip! Need more air storage? Add a companion tank to your network. Simply plumb it into the system as you would a pass-through filter.

Connecting an air compressor to the pipe system with a short, flexible hose lets you disconnect it should you need to take the compressor elsewhere. This hose also isolates compressor vibration, blocking it from transferring into the pipe network. A pass-through filter near the compressor traps most contaminants and water to keep the lines clean. To drain moisture from the tank, either take the compressor outside, or attach a small tube to the drain valve that reaches outside. Install a shut-off valve above the filter so you can unhook the compressor without discharging the entire pipe network.

Filter

Flexible hose

Tip! Prevent an air compressor from scooting due to vibration by placing it on a non-slip mat or securing it with cleats.

Airflow needs of pneumatic tools 1

2

■ Tire-inflation nozzle 1–2 cfm ■ 18-gauge brad nailer 1–2 cfm woodmagazine.com

3

4

5

6

7

8

9

10

11

■ Blower ■ Impact wrench nozzle ■ Die grinder (3⁄8 – 1⁄2") 1 ■ Finish/paint ( ⁄4") 2–3 cfm 5–8 cfm sprayer 4–6 cfm ■ 15-gauge 7–12 cfm finish nailer 2–3 cfm

12

13

14

15

■ Dual-action orbital sander 10–15 cfm

55

Warning! Do not use

Now for the pipe

PVC pipe, or PEX and similar plumbing fittings for compressed air. They’re not rated for high pressure and can fracture or explode under pressure.

Choose from steel, copper, or aluminum pipe to plumb a system, or even semiflexible rubber tubing approved for high pressure. Each has advantages and disadvantages and requires a different method of installation, but they all function well. We chose copper because it doesn’t rust, is readily available at

hardware stores and home centers, costs about the same as steel pipe, and can be easily modified later, if needed. Granted, you’ll need to learn to sweat/solder joints—the heart of copper plumbing—but with a little practice it becomes second nature.

How to sweat copper joints

1 Cut pipe sections to length with a tubing cutter, and then clean the ends. Clean the outside of the pipe with sandpaper or emery cloth.

4 Apply flux to the pipe end as well as the fitting. Slide the fitting onto the pipe, making sure to align it as needed to correspond with other fittings already installed. 56

Tip! To alter or expand your system, simply cut a pipe and install a new tee, or loosen an existing tee by heating it with the torch and making your changes.

fA typical propane torch works fine for sweating copper pipe, but an oxy/acetylene or MAP-gas (methylacetylene-propadiene) torch (as little as $70) gets the job done a lot faster. Buy a complete copper-sweating tool kit: woodmagazine.com/copperkit.

2 Use a deburring tool to remove the raised burr from inside the pipe.

5 Using a torch, heat the joint. When flux bubbles out, touch solder to the joint. As the solder melts, capillary action sucks it into the joint. Be sure to apply solder all around the joint.

3 Using a wire bristle brush, clean the inside of the fitting.

6 When finished, wipe off excess flux, which can corrode the pipe over time. Allow the pipe to cool before installing. WOOD magazine July 2017

Tip! Sweat together subassemblies, such as a hose-connection drop, before connecting them to the pipe network already in place on the wall. This reduces the amount of work done on a ladder or overhead.

fSave money by making your own hose hangers. woodmagazine.com/ achose

Fixtures fill out the field In addition to pipe, you’ll need a number of readily available fixtures to outfit the system. Tees and elbows let you turn, branch off, or add other fixtures. Wall-mounted stand-off brackets hold the pipe securely and leave 3–4" between the pipe and wall, necessary for attaching some fixtures and for soldering without burning the wall, right. You’ll need valves for turning on or off the air pressure at various places along the network. And quickconnect fittings provide the link between pipe and air hose, below. You’ll also want a pressure regulator at each drop, which allows you to control the air pressure at each hose separately without having to change the setting for the whole system at the compressor. For example, most finish nailers work best at 90 psi, but a sprayer might require only 40–50 psi. You can also add inline filters at each drop, but one at the main line near the compressor should be sufficient. In addition to filters, another (less-expensive) way to combat moisture is to install “drip legs.” These valves below tees provide straight paths for water to drain [Photos below]. We recommend installing one at every drop. Don’t skimp on the regulators and filters. You don’t want to risk damage to a tool or water in your sprayed finish, so opt for better quality components. Produced by Bob Hunter and Dave Ridgway with Sonny Tedder and Gary Harper of A.J. Allen Mechanical Contractors, Inc.

Stand-off brackets Quick connect

Stand-off bracket

Stand-offs provide elbow room, necessary when soldering on the wall, allowing you to get solder into the joint all around, while keeping the flame off the wall and ceiling. Sources Hose reels: Flexzilla 3⁄8" × 30', no. L8230FZ, $84.44; 3⁄8" × 50', no. L8250FZ, $85.01, amazon.com. Regulator: ARO 1⁄2" NPT 250 maximum psi, no. R37341-600-VS, $49.08, amazon.com. Inline filter: ARO 1⁄2" NPT 150 maximum psi, no. F35341-400-VS, $41.98, amazon.com.

fWe’ve made it easy to get all the air-system accessories (not including the copper fittings) in this article in one place. Go to woodmagazine.com/ plumbshop, update the quantities you need, and purchase them securely through amazon.com.

Shut-off valve

Drip leg

Regulator

Drain valve

A typical hose-connection drop tees off the pipe to the side with a valve, regulator, and quick-connect fitting. The drip leg keeps moisture from getting to the hose. woodmagazine.com

A hose reel makes for easy hose management at a drop. You can buy a reel with a swivel mounting bracket so it stores flat against the wall when not in use. 57

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TOOLS & MATERIALS

Hollow-ground bevel reflects curvature of wheel

SHOP-TESTED

Daily Grinders

Chisel

Tool rest

For shaping and sharpening hand-tool blades quickly, nothing tops a bench grinder. In most cases, you’ll still need to hone the edge with a waterstone, diamond stone, or sandpaper, but the grinder gets the rough work done. These tools create a hollow grind on chisels and plane irons (shown top right) that speeds up the honing process. Grinders are also great for sharpening turning chisels, which don’t need finely honed edges.

Delta 23-197, $130

fWheel diameter: 8" fWheels: 36- and 60-grit aluminum oxide

Although we’d never run this variable-speed grinder faster than its slowest speed (2,000 rpm) to avoid overheating tools, it runs smoothly without vibration. The tool rests adjust without wrenches (nice!). We’d prefer a finer-grit wheel than the 36-grit one it came with, and we found the angled drill-bit slot annoying when sharpening flat blades. 800-223-7278, deltamachinery.com

Rikon 80-808, $220

Best of the best

fWheel diameter: 8" fWheels: 60- and 120-grit aluminum oxide

A dedicated slow-speed (1,750 rpm) grinder, the 80-808 runs powerfully and smoothly, and it won’t heat up tools as quickly as faster machines. The solid tool rests adjust easily (although you’ll need one wrench), and the magnifying-lens guards and LED lamp really help visibility. (It also comes with standard guards.)

Craftsman 21154, $130

fWheel diameter: 6" fWheels: 60-grit aluminum oxide and wire bristle

The stone wheel works great for shaping tool edges, but for finer sharpening, we’d prefer a 120-grit wheel. The wire wheel comes in handy for cleaning tools and removing a sharpening burr, but we could live without it. Like the Delta 23-197, run this variable-speed machine at its slowest speed (2,000 rpm). We like its solid tool rests, including both flat and angled drill rests for the left side.

877-884-5167, rikontools.com 800-349-4358, craftsman.com

59

TOOLS & MATERIALS SHOP-TESTED

Shhhh! These compressors have a secret If you enjoy a loud air compressor, then stop reading here— these are not for you. But if you want a compressor that runs as quiet as normal conversation, then get to know the California Air Tools line. The three models shown here run between 67 and 70 decibels—about 20 decibels quieter than a typical oil-free compressor. The secret is in their two-cylinder, oil-free pumps, powered by slow-speed motors. (Single-cylinder compressors have to run twice as fast, creating more noise.) All of these three work well for powering nailers, blowing dust around, and inflating tires. The 41⁄2-gallon unit has twin aluminum tanks and weighs just 45 pounds; the other two have steel tanks. —Tested by Bob Hunter, Tools Editor

866-409-4681, californiaairtools.com 41⁄2-gallon tank, no. 4610AC, $200 51⁄2-gallon tank, no. 5510SE, $150 10-gallon tank, no. 10020C, $370

One hand, no cord, plenty of power 18-volt trim router, no. R86044B, $119

By running on a lithium-ion battery, this router eliminates the dangling power cord that can get in the way when routing. It has plenty of power for flush-trimming and routing edge profiles, and when using a Ridgid slim-pack battery (shown), felt well-balanced and easy to operate. (The bigger packs make the router just a bit more cumbersome.) Granted, the run time has a limit—depending on the battery-pack size and the bit you use—but a pair of battery packs should easily get you through a project. —Tested by Kevin Boyle, Senior Design Editor 866-539-1710, ridgidpowertools.com

62

continued on page 64

WOOD magazine July 2017

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Better Homes and Gardens® WOOD® magazine (ISSN-0743-894X); July 2017, Volume 34, No. 3, is published 7 times a year in March, May, July, Sept, Oct, Nov, Dec/Jan by Meredith Corporation, 1716 Locust Street, Des Moines, IA 50309-3023. Periodicals postage paid at Des Moines, IA, and at additional mailing offices. Subscription prices: $29.99 per year in the U.S.; $44.99 (U.S. dollars) in Canada; $49.99 (U.S. dollars) overseas. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: Send address corrections to Better Homes and Gardens WOOD, PO Box 37508, Boone, IA 50037-0508. In Canada: mailed under Publications Mail Sales Product Agreement No. 40069223; Canadian BN 12348 2887 RT. Return undeliverable Canadian addresses to Better Homes and Gardens WOOD, PO Box 882 STN Main, Markham, ON, L3P 9Z9. © Meredith Corporation 2017. All rights reserved. Printed in the U.S.A.

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